SERVICE SPECIFICATIONS Page MAINTENANCE... A-2 ENGINE MECHANICAL... A-3 TURBOCHARGER SYSTEM... A-7 EFI SYSTEM... A-8 COOLING SYSTEM... A-13 A-13 A-14 A-14 A-15 A-15 A-16 A-19 A-21 A-25 A-26 A-27 BRAKE SYSTEM... A-30 A-31 A-33 BODY... A-34 A-35 LUBRICATION SYSTEM... IGNITION SYSTEM... STARTING SYSTEM... CHARGING SYSTEM... CLUTCH... MANUAL TRANSMISSION (W58)... MANUAL TRANSMISSION (R154)... AUTOMATIC TRANSMISSION (A340E)... PROPELLER SHAFT... FRONT AXLE AND SUSPENSION... REAR AXLE AND SUSPENSION... STEERING... SRS AIRBAG... LUBRICANT...
A-2 SERVICE SPECIFICATIONS - Maintenance MAINTENANCE Engine Drive belt tension wl Borroughs drive belt tension gauge No. BT-33-73F or Nippondenso BTG-20 (95506-00020) Alternator PS pump A/C compressor New belt Used belt New belt Used belt New belt Used be1 t Coolant capacity MIT Engine oil capacity Spark plug Drain and refill AIT MIT A/T W/ Oil filter change w/o Oil filter change Type ND NGK Gap ND NGK 8.1 liters 8.0 liters 8.2 liters 8.1 liters 4.4 liters 4.1 liters 8.6 US qts 7.1 Imp. qts 8.5 US qts 7.0 Imp. qts 8.7 US qts 7.2 Imp. qts 8.5 US qts 7.1 Imp. qts 4.7 US qts 3.9 Imp. qts 4.3 US qts 3.6 Imp. qts 0.043 in. 0.031 in. Firing order Valve clearance (cold) Intake Exhaust 0.006-0.010 in. 0.008-0.01 2 in. Front and rear brake Pad thickness Disc thickness Front Rear Disc runout Parking brake Lining thickness Drum inner diameter Front axle and suspension Ball joint vertical play Upper Lower Steering wheel freeplay Torque specifications Front seat mounting bolt Front suspension member x Body Rear suspension member x Body (Front & Rear) 1.0 rnrn 21.0 mm 17.0 mm 0.13 mm 0.039 in. 0.827 in. 0.669 in. 0.005 in. 0.039 in. 7.52 in. 0 rnm 0 in. 0.3 mm 0.012 in 30 mm (1.18 in.) or less 375 kg-cm 27 ft-lb 37 N.m 1,300 kg-cm 94 ft-lb 12.1 N.m 1,840 kg-cm 133 ft-lb 180 N.m
ENGINE MECHANICAL Specifications SERVICE SPECIFICATIONS - Engine Mechanical A-3 Idle speed lntake rnanlfold vacuum 700 rpm 650 rpm 400 rnrnhg (15.75 in.hg, 53.3 kpa) or more Compression pressure at 250 rprn Differential of pressure between each cylinder 11.0 kg/cm2 156 psi 1,079 kpa 10.0 kg/crn2 142 psi 981 kpa 9.0 kg/cm2 128 psi 883 kpa 1.0 kg/crn2 (14 psi, 98 kpa) or less Cyllnder head Warpage Cylinder block side 0.10 rnrn 0.0039 in. Intake manifold side Lirnlt 0.10 rnrn 0.0039 in. Exhaust manifold side Llrnlt 0.10 rnrn 0.0039 In. Valve guide bore 11.000-11.027 rnrn 0.4331-0.4341 In. 01s 0.05 11.050-11.077 rnrn 0.4350-0.4361 In. Valve seat Refacing angle 30", 45", 60" Contacting angle 45" Contacting width 1.0-1.4 rnrn n. - -- Valve gulde bushlng lnslde dlameter Outslde d~ameter 6.010-6.030 rnrn 11.033-11.044 mrn 4 In. 8 In. 01s 0 05 11.083-11.094 rnrn 8 In. Replacing temperature (Cyl~nder head slde) -- -- -- 90 C Valve Valve overall length 98.15 rnrn 3.8642 in. Llrnlt 97.75 rnrn 3.8484 In. Valve face angle 44.5O Stem dlarneter Intake 5.970-5.985 rnrn 0.2350-0.23516 In Exhaust 5.965-5.980 rnrn 0.2348-0.235, 4 In. Stem 011 clearance Intake Exhaust 0.025-0.060 rnrn 0.030-0.065 rnrn 0.0010-0.00224 In. 0,0012-0.00216 In. Llrnlt lntake 0.08 rnrn 0.0031 In. Exhaust 0.10 mm 0.0039 In. Valve rnargln th~ckness 1.3 rnrn 0.051 In. Llrnit 0.5 rnrn 0.020 in. Valve sprlng Free length 41.64 rnrn 1.6394 in Installed length 35.0 mm 1.378 in. Installed load at 35 rnrn (1.378 in.) 16.0 kg 35 Ib 157 N Squareness 1.5 rnrn 0.059 in. Valve lifter Lifter diameter 27.975-27.985 rnrn 1.1014-1.10113 In. Oil clearance 0.015-0.046 rnrn 0.0006-0.00113 In. Llmlt 0.10 rnrn 0.0039 in.
A -4 SERVICE SPECIFICATIONS - Engine Mechanical Specifications (Cont'd) Intake, exhaust manifold and intake chamber Manifold surface warpage Intake Exhaust 0.10 rnrn 0.75 rnrn 0.0039 in. 0.0295 in. lntake chamber 0.50 rnrn 0.10 rnrn 0.0197 in. 0.0039 in. Camshaft Thrust clearance 0.08-0.19 rnrn 0.30 rnrn 0.0031-0.0075 in. 0.01 18 in. Journal oil clearance No. 1 0.035-0.072 rnrn 0.0014-0.0028 in. 0.13 rnrn 0.0051 in. NO. 2 - No. 7 0.025-0.093 rnrn 0.001 0-0.0037 in. 0.13 rnrn 0.0051 in. Journal diameter No. 1 26.949-26.965 rnrn 1.0610-1.0616 in. NO. 2 - NO. 7 26.888-26.975 rnrn 1.0586-1.0620 in. Circle runout 0.03 rnrn 0.0012 in. Cam lobe height Intake 38.16 rnrn 1.5024 in. 38.35 rnrn 1.5098 in. Exhaust 37.85 rnrn 38.00 rnrn 38.35 rnrn 1.4902 in. 1.4961 in. 1.5098 in. 38.00 rnrn 1.4961 in. Idler pulley tension spring Free length 69 rnrn 2.72 in. Pump drive shaft Thrust clearance Oil clearance 0.06-0.13 rnrn 0.30 rnrn 0.025-0.066 rnrn 0.08 rnrn 0.0024-0.0051 in. 0.01 18 in. 0.0010-0.0026 in. 0.0031 in. Journal diameter Front Rear 40.959-40.975 rnrn 32.959-32.975 rnrn 1.6126-1.6132 in. 1.2976-1.2982 in. Cylinder block Cylinder head surface warpage 0.05 rnrn 0.0020 in. Cylinder bore diameter Mark 0 Mark 1 Mark 2 82.990-83.000 mrn 83.001-83.010 rnrn 83.01 1-83.020 rnrn 3.2673-3.2677 in. 3.2677-3.2681 in. 3.2681-3.2685 in. Cylinder block main journal bore Mark 3 Mark 4 01s 0.50 Mark 1 Mark 2 83.021-83.030 rnrn 83.031-83.040 rnrn 83.24 mrn 83.74 mrn 64.024-64.030 mm 64.031-64.036 rnrn 3.2685-3.2689 in. 3.2689-3.2693 in. 3.2772 in. 3.2968 in. 2.5206-2.5209 in. 2.5209-2.521 1 in. UIS 0.25 Mark 3 64.037-64.042 rnrn 64.022-64.046 rnrn 2.521 1-2.5213 in. 2.5205-2.5215 in.
SERVICE SPECIFICATIONS - Engine Mechanical A-5 Specifications (Cont'd) Piston and piston ring Piston diameter Mark 0 82.900-82.910 rnrn 3.2638-3.2642 in. Mark 1 Mark 2 82.91 1-82.920 rnrn 82.921-82.930 rnrn 3.2642-3.2646 in. 3.2646-3.2650 in. Mark 3 82.931-82.940 rnrn 3.2650-3.2653 in. Mark 4 82.941-82.950 rnrn 3.2654-3.2657 in. 83.40-83.45 rnrn 3.2835-3.2854 in. Mark 0 82.910-82.920 rnrn 3.2642-3.2646 in. Mark 1 Mark 2 82.92 1-82.930 rnrn 82.931-82.940 mm 3.2646-3.2650 in. 3.2650-3.2653 in. Mark 3 82.941-82.950 rnrn 3.2654-3.2657 in. 01s 0.50 Mark 4 82.951-82.960 rnrn 83.41-83.46 rnrn 3.2658-3.2661 in. 3.2839-3.2858 in. Piston oil clearance 7 M-G E 0.08-0.10 rnrn 0.0031-0.0039 in. 0.13 rnrn 0.0051 in. 0.07-0.09 rnrn 0.0028-0.0035 in. 0.13 rnrn 0.0051 in. Piston ring end gap No. 1 0.23-0.38 rnrn 0.0091-0.0150 in. 0.68 rnrn 0.0268 in. 0.29-0.44 rnrn 0.01 14-0.0173 in. 0.74 rnrn 0.0291 in. No. 2 0.25-0.53 rnrn 0.0098-0.0209 in. 1.I3 rnrn 0.0445 in. Oil 0.10-0.40 rnrn 0.0039-0.0157 in. 1.OO rnrn 0.0394 in. 0.10-0.44 rnrn 0.0039-0.0173 in. 1.04 rnrn 0.0409 in. Ring groove clearance No. 1 No. 2 Piston pin installing temperature 0.03-0.07 rnrn 0.02-0.06 rnrn 60" c 0.0012-0.0028 in. 0.0008-0.0024 in. 140" F Connecting rod and bearing Thrust clearance 0.160-0.296 rnrn 0.3 rnrn 0.0063-0.01 17 in. 0.012 in. Big end inner diameter Mark 1 55.015-55.025 rnrn 2.1659-2.1663 in. Mark 2 55.026-55.035 mrn 2.1664-2.1667 in. Mark 3 55.036-55.045 rnrn 55.01 5-55.045 rnrn 2.1668-2.1671 in. 2.1659-2.1671 in. Connecting rod bearing center wall thickness Mark 1 Mark 2 1.490-1.495 rnrn 1.496-1.500 rnrn 0.0587-0.0589 in. 0.0589-0.0591 in. Mark 3 1.501-1.505 rnrn 0.0591-0.0593 in. Mark 4 1.506-1.510 rnm 0.0593-0.0594 in. Mark 5 1.511-1.515 rnrn 0.0595-0.0596 in. U/S 0.25 1.622-1.632 rnm 0.0639-0.0643 in. Bearing oil clearance 0.021-0.053 rnrn 0.0008-0.0021 in. 0.07 rnrn 0.0028 in. Pin oil clearance 0.005-0.01 1 rnrn 0.0002-0.0004 in. 0.02 rnrn 0.0008 in.
A-6 SERVICE SPECIFICATIONS - Engine Mechanical Specifications (Cont'd) Connecting rod and bearing (cont'd) Crankshaft and bearing Piston pin diameter Rod bend per 100 mm (3.94 in.) Rod twist per 100 mm (3.94 in.) Thrust clearance Thrust washer thickness 01s 0.125 Main journal oil cleanrance Main journal diameter Mark 0 Mark 1 Mark 2 U/S 0.25 Main bearing center wall thickness Mark 1 Mark 2 Mark 3 Mark 4 Mark 5 Crank pin diame Mark 0 Mark 1 Mark 2 U/S 0.25 Circle runout Main journal taper and out-of-round Check pin journal taper and out-of-round 0.8660-0.8665 in. 0.0020 in. 0.0059 in. 0.0020-0.0098 in. 0.01 18 in. 0.1152-0.1171 in. 0.1176-0.1196 in. 0.0012-0.0019 in. 0.0028 in. 2.3625-2.3627 in. 2.3622-2.3624 in. 2.3620-2.3622 in. 2.3516-2.3520 in. 0.0783-0.0784 in. 0.0784-0.0785 in. 0.0785-0.0786 in. 0.0787-0.0787 in. 0.0788-0.0789 in. 0.0836-0.0840 in. 2.0470-2.0472 in. 2.0466-2.0469 in. 2.0463-2.0466 in. 2.0364-2.0368 in. 0.0024 in. 0.0008 in. 0.0008 in. Flywheel Runout 0.004 in. Torque Specifications Part tightened I kg-cm ft-lb N.m - -- Camshaft timing pulley x Camshaft Oil pump drive pulley x Oil pump drive shaft Crankshaft x Crank pulley Crankshaft x Flywheel Crankshaft x Drive plate Air intake chamber x Intake manifold Air intake chamber x Air intake connector () Throttle body x Air intake connector Cylinder head x No. 1 and No. 2 cylinder head covers Cylinder head x No. 3 cylinder head cover Cylinder head x Cylinder block
Torque Specifications (Cont'd) SERVICE SPECIFICATIONS - Engine Mechanical, Turbocharger System A-7 Part tightened kg-cm ft-lb Cylinder head x Spark plug Cylinder head x No. 2 engine hanger Cylinder head x Heater union Cylinder head x EGR cooler Cylinder head x Camshaft bearing cap Cylinder head x intake manifold Cylinder head x Exhaust manifold Cylinder head x Distributor () Cylinder head x Cam position sensor () Connecting rod cap x Connecting rod Cylinder block x Main bearing cap Cylinder block x Timing belt case x Idler pulley Cylinder bloc' x Timing belt case Cylinder block x Oil pump drive shaft thrust plate Oil nozzle x Cylinder block 12 mm I4 mm TURBOCHARGER SYSTEM Specifications Turbocharger Turbocharging pressure M /T AIT Turbine shaft axial play Turbine shaft radial play 0.39-0.53 kg/cm2 (5.5-7.5 psi, 38-52 kpa) 0.34-0.42 kg/cm2 (4.8-6.0 psi, 33-41 kpa) 0.13 rnm (0.0051 in.) or less 0.18 mm (0.0071 in.) or less Torque Specifications Part tightened 1 kg-cm ft-lb N.m Turbocharger x Turbin outlet elbow Oil pipe x Turbocharger Water pipe x Turbocharger Oil pipe x Cylinder block (Bolt) Oil pipe x Cylinder block (Nut) Turbocharger stay x Turbocharger Turbocharger stay x Engine mounting bracket Turbocharger x Exhaust manifold 440 32 43 130 9 13 75 65 in.-lb 7.4 350 25 34 130 9 13 810 59 79 590 43 58 450 33 44
A-8 SERVICE SPEC1 FICATIONS - EF I System EFI SYSTEM Specifications Fuel pressure regulator Cold start injector Injector Fuel pressure at No vacuum at No vacuum Resistance Fuel leakage Resistance Injection volume Difference volume between each injector Fuel leakage 2.7-3.1 kg/crn2 (38-44 psi, 265-304 kpa) 2.3-2.8 kg/crn2 (33-40 psi, 226-275 kpa) 2-4R One drop or less of fuel per minute Approx. 13.8 R 2.0-3.8 R 69-85 cc (4.2-5.2 cu in.)/15 sec. 101-114 cc (6.2-7.0 cu in.1115 sec. 9 cc (0.31 cu in.) or less One drop or less of fuel per minute Resistance E2 -VS 200-600 R (Measuring plate fully closed) 20-1,200 R (Measuring plate fully open) 200-400 R Infinity (Measuring plate fully closed) Zero (Others) E2 - THA at -20 C (-4 F; 10-20 kr at 0 C (32 F) 4-7ka at 20 C (68 F) 2-3kR at 40 C (104"~) 0.9-1.3 kr at 60'~ (140~~) 0.4-0.7 kr E2 - THA at -20 C (-4 F) 10-20kR at 0 C (32 F) 4-7kR at 20'~ (68 F) 2-3kR at 40"~ (104"~) 0.9-1.3 kr at 60 C (140"~) 0.4-0.7 kr Clearance between stop screw and lever Between terminais 1 Resistance 0 mm (0 in.) I 0 mrn (0 in.) VTA - E2 1 0.2-1.2 kr I I 0.40 mm (0.0157 in.) 0.50 mrn (0.0197 in.) IDL - E2 i 2.3 kr or less -- 0.75 mm (0.0295 in.) 0.90 mm (0.0354 in.) IDL - E2 Infinity.- Throttle valve fully opened posit~on VTA - E2 3.5-10.3 k52 VC - E2 4.25-8.25 kr
SERVICE SPECIFICATIONS - EFI System A-9 Specifications (Cont'd) ISC valve Resistance Solenoid resistor () - Cold start injector time switch Resistance No. 10 +B - 2 No. 30 Resistance STA - STJ STA - Ground below 15 C (59 F) above 30'~ (86'~) 3 R each Water temp. sensor Resistance at -20 C (-4 F) at 0 C (32 F) at 20 C (68 F) at 40 C (104 F) at 60 C (140 F) at 80 C (176 F) Fuel control VSV () - -. -- Fuel pump resistor Resistance Resistance Approx. 0.7 R Oxygen sensor Heater resistance Sub-oxygen sensor [ (Calif. only)] EGR gas temp. sensor (Calif. only) Heater resistance Resistance at 20 C (68 F) ECU HINT: Perform all voltage and resistance measurements with the computer connected. Verify that the battery voltage is 11 V or above when the ignition switch is ON. Voltage Terminals BATT - El Condition - Voltage (V) I10-14 IG SW - El ) Ignition SW ON M-REL - El lgnition SW ON +B(+BI ) - El I ignition SW ON IDL - E2 I Ignition SW ON 1 Throttle valve open IDL - E2.. lgn~t~on SW ON () 1 Throttle valve open
A-10 SERVICE SPECIFICATIONS - EFI System Specifications (Cont'd) ECU (contrd) 1 Terminals Condition Voltage (V) Ignition SW ON - 4-6 VTA - E2 lgnition SW ON Throttle valve fully closed Throttle valve fully open 0.1-1.0 3.2-4.2 lgnition SW ON Measuring plate fully closed I 3.7-4.3 Measuring plate fully open 0.2-0.5 Idling 3,000 rpm Body *' KS - ground Body 1 *' VC - ground lgnition SW ON Cranking or running lgnition SW ON No. 10 EO1 No. 20 - lgnition SW ON No. 30 E02 7 THA - E2 Ignition SW ON Ignition SW ON Intake air temperature 20'~ (68'~) Coolant temperature 80'~ (176'F) 1-3 0.1-1.0 1 IGT - El Cranking Ignition SW ON 6-14 0.7-1.O Idling Ignition SW ON 1 9-14 No trouble ("CHECK ENGINE" warning light off) and engine running lgnition SW ON lgnition SW ON lgnition SW ON lgnition SW ON Air conditioning ON Check connector TE1 - El not connect Check connector TEI - El connect Shift position P or N range Ex. P or N range Clutch pedal not depressed Clutch pedal depressed 0 10-14
SERVICE SPECIFICATIONS - EFI System A-1 1 Specifications (Cont'd) ECU (cont'd) 1 Terminal 1 Condition 1 Voltage (v) - El " 3 ~ ~ ~ Ignition SW ON Defogger SW OFF 10-14 Defogger SW ON 0 "3LP - El Headlight SW OFF Headlight SW ON 10-14 0 Resistance Terminals ~ Condition 1 Resistance (R) IDL - E2 - Throttle valve fully open Throttle valve fully closed Infinity 2,300 or less VTA - E2 Throttle valve fully open Throttle valve fully closed VC - E2 VS - E2 Measuring plate fully closed Measuring plate fully open - 4,250-8,250 200-600 20-1,200 THA - E2 1 Intake air temperature 20'~ (68'~) THW - E2 Gl,G2 - G s Coolant temperature 80'~ (176'~) - 200-400 140-180 - -- Fuel cut rpm W/ Vehicle speed 0 km/h and coolant temp. 80'~ (176'~) Fuel cut rpm Fuel return rpm Fuel cut rprn Fuel return rprn 1,800 rprn 1,200 rprn 1,600 rprn 1,200 rprn *' only *' only *3 ex. A/T
A-12 SERVICE SPECIFICATIONS - EFI System Torque Specifications Part tightened Fuel line Union bolt type Flare nut type Fuel pump x Fuel tank Cold start injector x Air intake chamber Cold start injector tube x Cold start injector Cold start injector tube x Delivery pipe Fuel pressure regulator x Delivery pipe No. 2 fuel pipe x Delivery pipe Delivery pipe x Cylinder head No. 1 fuel pipe x Delivery pipe No. 1 fuel pipe x Fuel pipe support Air intake connector x Air intake chamber () Fuel sender gauge x Fuel tank Fuel tank bracket x Body Fuel tank band bracket x Body Fuel tank band x Body Fuel tank drain plug Throttle body x Air intake chamber ISC valve x Air intake chamber kg-cm ft-lb
SERVICE SPECIFICATIONS - Cooling System, Lubrication System A-13 COOLING SYSTEM Specifications Engine coolant capacity See page A-2 Thermostat Valve opening temperature Valve lift at 1 0 0 (212'~) ~ ~ 86-90"~ 187-194 F 8 mm (0.31 in.) or more Radiator Relief valve opening pressure 0.75-1.05 kg/cm2 (10.7-14.9 psi, 74-103 kpa) 0.6 kg/cm2 8.5 psi 59 kpa Torque Specifications Part tightened Drain plug Water outlet x Water outlet housing Water pump x Cylinder block 10 mm 12 mm kg-cm ft-lb N.m 350 25 34 80 69 in.-lb 7.8 90 78 in.-lb 8.8 195 14 2 0 LUBRICATION SYSTEM Specifications Engine oil capacity Oil pressure -- at Idle speed at 3,000 rpm See page A-35 0.3 kg/cm2 (4.3 psi, 29 kpa) or more 2.5-5.0 kg/cm2 36-71 psi 245-490 kpa Oil pump Body clearance 0.105-0.175mm 0.0041-0.0069 in. 0.2 mm 0.008 in. Side clearance 0.03-0.09 mm 0.0012-0.0035 in. 0.15 mm 0.0059 in. Gear backlash 0.5-0.6 mm 0.020-0.024 in. Relief valve operating pressure 0.9 mm 0.035 in. 4.4-5.0 kg/cm2 63-71 psi 431-490 kpa Torque Specifications Part tightened kg-cm ft-lb N.m Engine oil drain plug Oil pump cover x Oil pump body Relief valve x Oil pump cover Oil pump x Cylinder block Oil pump strainer x Oil pump body Oil pump outlet pipe x Oil pump Oil pump outlet pipe x Union 350 75 375 220 130 350 350 25 65 in.-lb 27 16 9 25 25 34 7.4 37 22 13 34 34 Oil pan x Cylinder block 1 130 9 13 Oil pressure regulator plug 375 27 37 Oil filter bracket x Cylinder block 500 36 49
A-14 SERVICE SPECIFICATIONS - Ignition System, Starting System IGNITION SYSTEM Ignition timing Spark plug TIM in N range Type ND NGK ND NGK Gap 10" BTDC @ Idle [Check connector terminals TEI and El connec PO1 6R BCPR5EP11 PQ20R-P8 BCPRGEP-N8 1.1 mm 0.043 in. 1.3 mrn 0.051 in. 0.8 mm 0.031 in. 1.0 mm 0.039 in. High-tension cord Resistance 25 kr Der cord lgnition coil Primary coil resistance Secondary coil resistance ( only) Distributor () or cam position sensor () Air gap GI, G2 and NE pickups Pickup coil resistance 0.2 mm (0.008 in.) or more 0.2-0.4 mm 0.008-0.016 in. GI and G2 pickups NE pickup STARTING SYSTEM Starter Rated voltage and output power No-load characteristic Current I rpm Brush length Commutator Outer diameter Undercut depth Circle runout Spring installed load 1 12V 1.4kW 90A or less at 11.5 V 3,500 rpm or more 15.5 mm 0.610 in. 10.0 mm 0.394 in. 30 mm 1.18 in. 29 mm 1.14 in. 0.6 mm 0.024 in. 0.2 mm 0.008 in. 0.05 mm 0.0020 in. 1.79-2.41 kg (3.9-5.3 lb, 18-24 N) 1.2 kg 2.6 1b 12 N
CHARGING SYSTEM SERVICE SPECIFICATIONS - Charging System, Clutch A-15 Drive belt tension See page A-2 Battery specific gravity When fully charged at 20'~ (68OF) Alternator Rated output ampere 12 V 70 A 12 V 80 A Rotor coil resistance 2.8-3.0a Slip ring diameter 14.2-14.4 rnm 0.559-0.567 in. 12.8 mm 0.504 in. Bush exposed length 10.5 mm 0.413 in. Alternator regulator (IC) -. Regulator voltage 1.5 mm 0.059 in. CLUTCH Specifications Pedal height (from asphalt sheet) Push rod play at pedal top Pedal freeplay Clutch release point (from pedal stroke end position to release point) 157-167mm 1-5mm 5-15mm 25 mm (0.98 in.) or more 6.1 8-6.57 in. 0.04-0.20 in. 0.20-0.59 in. Disc rivet head depth Disc runout Diaphragm spring out-of-alignment 0.012 in. 0.031 in. 0.020 in. Diaphragm spring finger wear Depth 0.024 in. Width 0.197 in. Flywheel runout 0.008 in. Torque Specifications Part tightened Clutch cover x Flywheel Reservoir tank set bolt Clutch line tube union I kg-cm 195 ft-l b Flexible hose x Release cylinder () Bleeder plug Flywheel set bolt Release cylinder x Clutch housing
A-16 SERVICE SPEC1 F ICATIONS - Manual Transmission (W58) MANUAL TRANSMISSION (W58) Specifications Output shaft 2nd gear journal diameter 3rd gear journal diameter Flange thickness Runout 1st gear inner race flange thickness 1st gear Inner race outer diameter Counter gear Center bearlng journal outer diameter Counter 5th gear journal outer diameter Gear thrust clearance lst, 2nd & 3rd Counter 5th Llmlt Llmit 1.6870 in. 1.4882 in. 0.2205 in. 0.0024 in. 0.1850 In. 1.6870 in. 1.1772 in. 1.0571 in. 0.0039-0.0098 In. 0.0118 in. 0.0039-0.0161 In. 0.0181 in. Gear oil clearance 1st & 2nd 0.0004-0.0024 in. Llmlt 0.0059 in. 0.0024-0.0041 In. 0.0079 in. Counter 5th 0.0004-0.0024 In. Llmlt 0.0059 in. Shift fork to hub sleeve clearance 1.0 mm 0.039 in. Synchronizer ring to gear clearance 0.7-1.7 mm 0.028-0.067 In. L~mlt 0.5 rnm 0.020 in. Input shaft snap ring thickness Mark 1 0.0807-0.0827 In. 2 0.0827-0.0846 in. 3 0.0846-0.0866 in. 4 0.0866-0.0886 in. 5 0.0886-0.0906 in. 11 0.0906-0.0925 in. 12 0.0925-0.0945 In.
Specifications (Cont'd) SERVICE SPECIFICATIONS - Manual Transmission (W58) A-17 Output shaft snap ring thickness Front Rear Reverse gear Mark D 11 12 13 14 15 Mark 8 9 10 11 12 13 14 15 Mark 5 11 12 13 14 15 16 17 18 19 20 21 22 23 1.80-1.85 rnrn 1.86-1.91 rnrn 1.92-1.97 rnrn 1.98-2.03 rnrn 2.04-2.09 rnrn 2.10-2.15 rnrn 2.31-2.36 rnrn 2.37-2.42 rnrn 2.43-2.48 rnrn 2.49-2.54 rnrn 2.55-2.60 rnrn 2.61-2.66 rnrn 2.68-2.73 rnrn 2.74-2.79 rnrn 2.25-2.30 rnrn 2.30-2.35 rnrn 2.35-2.40 rnrn 2.40-2.45 rnrn 2.45-2.50 rnrn 2.50-2.55 rnrn 2.55-2.60 rnrn 2.61-2.66 rnrn 2.67-2.72 rnrn 2.73-2.78 rnrn 2.79-2.84 rnrn 2.85-2.90 rnrn 2.91-2.96 rnm 2.97-3.02 rnrn 0.0709-0.0728 in. 0.0732-0.0752 in. 0.0756-0.0776 in. 0.0780-0.0799 in. 0.0803-0.0823 in. 0.0827-0.0846 In. 0.0909-0.0929 in. 0.0933-0.0953 in. 0.0957-0.0976 in. 0.0980-0.1000 in. 0.1004-0.1024 in. 0.1028-0.1047 in. 0.1055-0.1075 in. 0.1079-0.1098 In. 0.0886-0.0906 in. 0.0906-0.0925 in. 0.0925-0.0945 In. 0.0945-0.0965 in. 0.0965-0.0984 In. 0.0984-0.1004 In. 0.1004-0.1024 in. 0.1028-0.1047 In. 0.1051-0.1071 in. 0.1075-0.1094 ~ n. 0.1098-0.1118 ~ n. 0.1122-0.1142 in. 0.1146-0.1165 in. 0.1169-0.1189 in.
A-18 SERVICE SPECIFICATIONS - Manual Transmission (W58) Specifications (Cont'd) Counter gear snap ring thickness Front Rear No. 3 clutch hub Oil seal drive in depth Mark 1 2 3 4 5 6 7 Mark 1 2 3 4 5 6 7 Mark 2 3 4 5 Front bearing retainer Speedometer driven gear 0.0807-0.0827 in. 0.0827-0.0846 in. 0.0846-0.0866 in. 0.0866-0.0886 in. 0.0886-0.0906 ~ n. 0.0906-0.0925 in. 0.0925-0.0945 in. 0.0748-0.0768 in. 0.0772-0.0791 in. 0.0795-0.0815 in. 0.0819-0.0839in. 0.0843-0.0862 in. 0.0866-0.0886 in. 0.0890-0.0909 in. 0.0811-0.0831 in. 0.0835-0.0854 in. 0.0858-0.0878 in. 0.0882-0.0902 in. 0.449-0.472 in. 0.98 in. 'orque Specifications Part tightened kg-cm ft-l b N.m Shift fork set bolt Straight screw plug Reverse idler gear shaft stopper bolt Front bearing retainer set bolt Extension housing x Intermediate plate Restrict pin Shift lever housing x Shift and select lever shaft Shift lever retalner x Extension housing Drain and filler plugs Back-up light switch Clutch housing x Transmission case Center bearing retainer x lntermediate plate Clutch housing x Engine Engine rear mounting bolt Stiffener plate bolt
SERVICE SPECIFICATIONS - Manual Transmission (R 154) A-19 MANUAL TRANSMISSION (R154) Specifications Output shaft 1st gear journal diameter 38.860 mm 1.5299 in. 2nd gear journal diameter 46.860 rnrn 1.8499 in. 3rd gear journal diameter 37.860 rnrn 1.4905 in. Flange thickness 4.70 rnrn 0.1 850 in. Runout 0.06 rnrn 0.0024 in. Counter gear Roller bearing journal diameter 27.860 rnrn 1.0968 in. Gear thrust clearance 1 s t 0.10-0.45 mm 0.0039-0.0177 in. 0.50 rnrn 0.0197 in. 0.10-0.25 mm 0.0039-0.0098 in. 0.30 mm 0.01 18 in. Counter 5th 0.10-0.35 mm 0.0039-0.0138 in. 0.40 rnrn 0.0157 in. Gear oil clearance I st 0.020-0.073 mm 0.0008-0.0029 in. 0.16 rnrn 0.0063 in. 2nd. 3rd & Counter 5th 0.01 5-0.068 mm 0.0006-0.0027 in. 0.16 mm 0.0063 in. Shift fork to hub sleeve clearance 1.0 rnrn 0.039 in. Synchronizer ring to gear clearance 0.8-1.6 rnrn 0.031-0.063 in. 0.6 mm 0.024 in. Input shaft snap ring thickness Mark A 2.10-2.15 mm 0.0827-0.0846 in. B 2.15-2.20 rnrn 0.0846-0.0866 in. C 2.20-2.25 rnrn 0.0866-0.0886 in. D 2.25-2.30 rnrn 0.0886-0.0906 in. E 2.30-2.35 mm 0.0906-0.0925 in. F 2.35-2.40 rnrn 0.0925-0.0945 in. G 2.40-2.45 mm 0.0945-0.0965 in. Counter gear snap ring (Front bearing) Mark A 2.00-2.05 rnrn 0.0787-0.0807 in. B 2.05-2.1 0 rnrn 0.0807-0.0827 in. C 2.10-2.15 rnrn 0.0827-0.0846 in. D 2.15-2.20 mm 0.0846-0.0866 in. E 2.20-2.25 mm 0.0866-0.0886 in.
A-20 SERVICE SPECIFICATIONS - Manual Transmission (R 154) Specifications (Cont'd) Output shaft snap ring thickness No. 2 clutch hub No. 1 clutch hub Rear Oil seal drive in depth Mark A B C D E F G Mark A B C D E F G Mark A B C D E F G H J K L M N 0 R S Front bearing retainer Speedometer driven gear P 0.0709-0.0728 in. 0.0728-0.0748 in. 0.0748-0.0768 in. 0.0768-0.0787 in. 0.0787-0.0807 in. 0.0807-0.0827 in. 0.0827-0.0846 in. 0.0906-0.0925 in. 0.0925-0.0945 in. 0.0945-0.0965 in. 0.0965-0.0984 in. 0.0984-0.1004 in. 0.1004-0.1024 in. 0.1024-0.1043 in. 0.1043-0.1063 in. 0.1063-0.1083 in. 0.1083-0.1102 in. 0.1102-0.1122 in. 0.1 122-0.7 142 in. 0.1 142-0.1161 in. 0.1161-0.1181 in. 0.1181-0.1201 in. 0.1201-0.1220 in. 0.1220-0.1240 in. 0.1240-0.1260 in. 0.1260-0.1280 in. 0.1280-0.1299 in. 0.1299-0.1319 in. 0.1319-0.1339 in. 0.1339-0.1358 in. 0.1358-0.1378 in. 0.441-0.480 in. 0.98 in.
SERVICE SPEC1 FICATIONS - Manual Transmission (R 154), Automatic Transmission (A340E) A-21 Torque Specifications Part tightened kg-cm ft-lb N.m Reverse shift arm bracket Rear bearing retainer x Intermediate plate Counter gear rear lock nut Shift fork x Shift fork shaft Straight screw plug Front bearing retainer x Transmission case Transmission case x Extension housing Shift lever housing bolt Clutch housing x Transmission case Oil receiver x Extension housing Back-up light switch Restrict pin Shift lever retainer x Extension housing Clutch housing x Engine Clutch cover x Flywheel Clutch hous~ng cover bolt Engine rear mounting bolt Stiffener plate bolt AUTOMATIC TRANSMISSION (A340E) Specifications Line pressure (wheel locked) Engine idling D range 3.5-4.3 kg/cm2 50-61 psi At stall (Throttle valve fully opened) Engine idling R range D range R range D range 4.9-6.1 kg/cm2 70-87 psi 8.8-11.5 kg/cm2 125-164 psi 12.2-15.9 kg/cm2 174-226 psi 4.1-4.9 kg/cm2 58-70 psi At stall (Throttle valve fully opened) Engine stall revolution Time lag N range + N range + Engine idling speed (A/C OFF) Throttle cable adjustment R range D range R range D range R range N range 5.0-6.2 kg/cm2 71-88 psi 12.3-15.0 kg/cm2 175-213 psi 15.1-18.8 kg/cm2 215-267 psi 2,200 k 150 rpm 2,500 * 150 rpm Less than 1.2 seconds Less than 1.5 seconds 700 rpm 650 rpm Throttle valve fully opened Torque converter installing Between boot end face and inner cable stopper 0-lmrn 0-0.04 in. Drive plate runout Torque converter sleeve runout 0.0079 in. 0.01 18 in.
A-22 SERVICE SPECIFICATIONS - Automatic Transmission (A340E) Specifications (Cont'd) Shift point () km/h (mph) Throttle valve fully open [ ] Fully closed D range Lock-up point () km/h (mph) I Throttle valve openlng 5% I Lock-up ON I Lock-up OFF D range PWR - 73-78 (45-48) 63-66 (39-41 ) - 68-7 2 (42-45) 57-61 (35-38) * O/D switch OFF Shift point () km/h (rnph) D range 1 NORM 1 PWR 1 -+ 2 40-44 (25-27) 47-51 (30-32) Throttls valve fully open [ ] Fully closed 2 -+ 3 94-99 (58-62) 102-111 (63-69) 3-+ 0/D 149-159 (93-99) 173-183 (108-1 14) [3-+O/DI [O/D-+31 38-41 28-32 (24-25) 1 (17-20] 45-50 (28-31 ) 28-32 (1 7-20) O/D + 3 143-153 (89-95) 166-177 (103-110) 3 + 2 2 -+ 1 86-94 34-39 (53-58) 1 (21-24) 95-103 (59-64) 41-45 (25-28) Lock-up point () km/h (mph) NORM 40-44 110-118 2 range I PWR (25-27), (68-73) NORM range pwr I - - - - 102-1 11 34-39 (63-69) (21-24) I I I I I I 1 I I - Throttle valve opening 5% Lock-up ON Lock-up OFF D range NORM PWR - - 80-85 (50-53) 80-85 (50-53) 60-65 (37-40) 69-73 (43-45) - - 74-79 (4649) 74-79 (46-49) 57-62 (35-39) 63-67 (39-42) * O/D switch OFF Oil pump Body clearance Tip clearance Side clearance 0.07-0.15 mm 0.0028-0.0059 in. 0.3 mm 0.012 in. 0.11-0.14 mm 0.0043-0.0055 in. 0.3 mm 0.012 in. 0.02-0.05 mm 0.0008-0.0020 in. 0.1 mm 0.004 in.
Specifications (Cont'd) SERVICE SPECIFICATIONS - Automatic Transmission (A340E) A-23 Bushing bore 011 pump body Stator shaft (FR) (RR) O/D direct clutch drum O/D planetary gear D~rect clutch drum Forward clutch drum Front planetary ring gear Planetary sun gear Transmission case Extension housing 1.5035 in. 0.8496 in. 1.0661 in. 1.0673 in. 0.4437 in. 2.1256 in. 0.9480 in. 0.9480 in. 1.0661 in. 1.5035 in. 1.5783 in. Flange thickness O/D direct clutch (Co) No. 21 No. 20 No. 19 No. 18 No. 17 No. 16 Direct clutch (C2) No. 33 No. 32 No. 31 No. 30 No. 29 No. 28 No. 27 O/D brake (Bo) No. 26 No. 25 No. 12 No. 24 No. 11 No. 23 None First and Reverse Brake (Bg) No. 50 No. 51 No. 52 No. 53 No. 54 No. 55 0.122 in. 0.126 in. 3.3 mm 0.130 in. 3.4 rnrn 0.134 in. 3.5 mm 0.138 in. 3.6 rnrn 0.142 in. 3.0 rnrn 0.118 in. 3.1 mm 0.122 in. 3.2 rnrn 0.126 in. 3.3 mm 0.130 in. 3.4 mm 0.134 in. 3.5 rnrn 0. I38 in. 3.6 mm 0.142 in. 0.146 in. 3.3 mm 3.5 mm 0.138 in. 3.6 mm 0.142 in. 3.7 mm 0.146 in. 3.8 mm 0.150 in. 3.9 mm 0.154 in. 4.0 mm 0.157 in. 5.0 mm 0.197 in. 4.8 mm 0.189 in. 4.6 mm 0.181 in. 4.4 mm 0.173 in. 4.2 mm 0.165 in. 4.0 mm 0.157 in. Clutch piston stroke O/D direct clutch (Co) Direct clutch (C2) Forward clutch (C,) 1.85-2.15 mm 0.0738-0.0846 in. 1.37-1.60 mm 0.0539-0.0630 in., 3.42-3.93 rnm 0.1346-0.1547 in. 3.73-4.59 rnm 0.1469-0.1807 in. Brake piston stroke O/D brake (Bo) 1.40-1.70 rnm 0.0551-0.0669 in. 1.75-2.05 mm 0.0689-0.0807 in. Second coast brake (B,) 1.5-3.0 mm 0.059-0.1 18 in.. Brake pack clearance Second brake (B2) First and reverse brake (B3) 0.62-1.98 mm 0.0244-0.0780 in. 0.60-1.12 mm 0.0236-0.0441 in. 0.70-1.22 rnm 0.0276-0.0480 in.
A-24 SERVICE SPECIFICATIONS - Automatic Transmission (A340E) Specifications (Cont'd) Valve body spring Free length rnrn (in.) Coil outer diameter rnrn (in.) Total \lo. of coils Color (Upper valve body) Down-shift plug Throttle valve 3-4 shift valve Second coast modulator valv Lock-up relay valve Secondary regulator valve Cut-back valve 2-3 shift valve Low coast modulator valve (Lower valve body) Check valve Pressure relief valve 1-2 shift valve Primary regulator valve Accumulator control valve 7M-GTI Output shaft thrust play Yellow Blue White Purple Orange Red Light Gr Blue None Purple Pink None None Purple None White Yellow 0.27-0.86 rnrn 0.0106-0.0339 in -- Second coast brake piston rod length 71.4 rnrn 72.9 rnrn 2.811 in. 2.870 in. Accumulator piston spring Free length rnrn (in.) Coil outer diameter rnrn (in.) Color Upper lnner Cz Outer 7M-GI 7M-G' Outer lnner 19.9 (0.783) 19.9 (0.783) Light G 42.1 (1.657) 1 ' 14.7 (0.579) Pink 70.3 (2.768) 20.2 (0.795) 1 Pink I I 62.0 (2.441) 1 16.0 (0.630) 1 Green 20.9 (0.823) Orange 14.0 (0.551) Yellow Planetary pinion gear thrust clearance O/D planetary gear Front planetary gear Rear planetary gear Max. Max. Max 0.20-0.60 rnrn I.OO rnrn 0.20-0.60 rnrn 1.00 rnrn 0.20-0.60 rnrn I.OO rnrn 0.0079-0.0236 in. 0.0394 in. 0.0079-0.0236 in. 0.0394 in. 0.0079-0.0236 in. 0.0394 in.
SERVICE SPEC1 FlCATlONS - Automatic Transmission (A340E), Propeller Shaft A-25 Torque Specifications Part tightened kg-cm ft-lb N.m Engine x Transmission Transmission housing x Transmission case Extension housing x Transmission case Parking lock pawl bracket O/D support x Transmission case Oil pump x Transmission case Oil pump body x Stator shaft Valve body x Transmission case Oil strainer Oil pan Speed sensor Speedometer driven gear lock plate Union Cooler pipe union nut Drive plate x Crankshaft Torque converter x Drive plate Neutral start switch 10 mm 12 mm Bolt Nut Control shaft lever PROPELLER SHAFT Specifications Bearing axial play Runout Llmit Snap ring thickness Mark or color 1 2 3 Brown Blue 6 7 8 0.0020 in. 0.031 in. 0.0827-0.0846 in. 0.0846-0.0866 in. 0.0866-0.0886 in. 0.0886-0.0906 in. 0.0906-0.0925 in. 0.0925-0.0945 in. 0.0945-0.0965 in. 0.0965-0.0984 in. Torque Specifications Part tightened Propeller shaft x Differential Intermediate shaft x Propeller shaft Center support bearlng x Body Intermediate shaft x Center bearlng x Joint flange 1st 2nd 3 rd kg-cm ft-l b N.m 750 54 74 750 54 74 500 36 49 1,850 134 181 Loosen nut 700 51 69
A-26 SERVICE SPECIFICATIONS - Front Axle and Suspension FRONT AXLE AND SUSPENSION Specifications - - i Cold tire inflation pressure Front wheel alignment Wheel lateral runout Toe-in Camber Tire size 225150 VR 16 Steering axis inclination Caster 1 Side slip Tie rod end left-right error Wheel angle Hub bearing axial direction play Shock absorber control rod starting torque Ball joint rotation condition Ball joint rotation condition Max. Inspection Adjustment Inspection Adjustment Left-right error Inspection Left-right error -- Inspection Adjustment Left-right error I Inside wheel Outside wheel at 20" (Outside wheel) Upper ball joint Lower ball joint Upper ball joint Lower ball joint Limi Limi Limi Inflation pressure Front 2.2 (32, 220) kg/cm2 (psi, kpa) 0 + 2 mm (0 + 0.08 in.) 0 + 1 mm (0 + 0.04 in.) -- - -- -0" 10' + 45' -- - - 30' 10 55' + 45' 30' 7'40' + 45' 7'40' + 30' 30' Rear 2.2 (32, 2201 --. Less than 3.0 mm/m (0.1 18 in.13.3 ft) 21 "00' (Inside wheel) 1.2 mrn 0.047 in. 1.5 mm 0.059 in. 0.05 mm 0.0020 in. 200 g-cm 0.17 in.-lb 0.02 N.m 10-35 kg-cm 8.7-30.0 in.-lb 1.0-3.4 N,m 0-5 kg-cm 0-4.3 in.-lb 0-0.5 N.m 0 mm 0 in. 0.3 rnm 0.012 in. Torque Specifications Part tightened kg-cm ft-lb N.m Hub nut Tie rod end clamp bolt Front and rear adjusting cam bolt Axle hub lock nut Lower ball joint x Steering knuckle Tie rod end x Steering knuckle Steering knuckle x Upper suspension arm Lower ball joint x Lower suspension arm Brake hose bracket x Steering knuckle Disc brake caliper x Steering knuckle Speed sensor set bolt Front shock absorber x Body Front shock absorber x Lower suspension arm Upper suspension arm mounting nut Piston rod lock nut Stabilizer link x Lower suspension arm Stabilizer link x Stabilizer bar Stabilizer bar bracket x Body
REAR AXLE AND SUSPENSION Specifications SERVICE SPECIFICATIONS - Rear Axle and Suspension A-27 Rear wheel al~gnment lnspect~on Adjustment Left-right error 4+2rnm (0.16 * 0.08 in.) 4+lmm (0.16 * 0.04 in.) Rear axle hub Bearing axial direction play Axle shaft flange runout L~mit 0.05 mm 0.0020 in. 0.05 mm 0.0020 in. Dr~ve shaft Drive shaft length 551.8-554.8 mm 21.724-21.824 in. Differential Drive pinlon bear~ng preload Total preload Drlve plnlon to rlng gear backlash P~n~on gear to s~de gear backlash Rlng gear runout Compan~on flange runout Llmlt at Starting New bearing Reused bearing at Starting Llm~t Lateral runout Radlal runout Ring gear ~nstall~ng temperature Dr~ve plnlon 011 seal dr~ve In depth S~de gear 011 seal dr~ve In depth S~de gear shaft runout Side gear thrust washer thickness (Conventional 2 plnion type) (Conventional 4 pinion type) (LSD) Max l~mlt Drive pinion adjusting plate washer thickness 10-16 kg-cm (8.7-13.9 in.-lb, 1.0-1.6 N,m) 5-8 kg-cm (4.3-6.9 in.-lb, 0.5-0.8 N,m) Add dr~ve p~nion bearing preload 4-6 kg-cm (3.5-5.2 in.-lb, 0.4-0.6 N.m) 0.13-0.18 mm '0.0051-0.0071 in. 0.05-0.20 mm 0.0020-0.0079 in. 0.1 mm 0.004 in. 0.1 mm 0.004 ~ n. 0.1 mm 0.004 in. 90-1 1 0"~ 194-230" F 1.5 mm 0.059 in. Flash the carrler end surface 0.2 mm 0.008 In. 1.58-1.62 mm 1.68-1.72 mm 1.78-1.82 mm 0.9 mm 1.0 mm 1.1 mm 1.2 rnm 1.3 mm 0.15 mrn 0.20 mm 0.25 mm 0.30 mm 0.35 mm 1.70 mm 1.73 mm 1.76 mm 1.79 mm 1.82 mm 1.85 mm 1.88 mm 0.0622-0.0638 in. 0.0661-0.0677 in. 0.0701-0.07 I7 in. 0.035 in. 0.039 in. 0.043 in. 0.047 in. 0.051 in. 0.0059 in. 0.0079 in. 0.0098 in. 0.01 18 in. 0.0138 in. 0.0669 in. 0.0681 in. 0.0693 in. 0.0705 in. 0.0717 in. 0.0728 in. 0.0740 in.
A-28 SERVICE SPECIFICATIONS - Rear Axle and Suspension Specifications (Cont'd) Differential (cont'd) Drive pinion adjusting plate washer thickness (cont'd) 1.91 mm 1.94 mm 0.0752 in. 0.0764 in. 1.97 mm 0.0776 in. 2.00 mm 0.0787 in. 2.03 mm 0.0799 in. 2.06 mm 0.081 1 in. 2.09 mm 0.0823 in. 2.12 mm 0.0835 In. 2.15 mm 0.0846 in. 2.18 mm 0.0858 in. 2.21 mm 0.0870 in. 2.24 mm 0.0882 in. 2.27 mm 0.0894 in. 2.30 mm 0.0906 in. 2.33 mm 0.0917 in. Side bearing adjusting plate thickness 2.57-2.59 mm 0.1012-0.1020 in. 2.60-2.62 mm 2.63-2.65 mm 0.1024-0.1031 in. 0.1035-0.1043 in. 2.66-2.68 mm 0.1047-0.1055 in. 2.69-2.71 rnm 0.1059-0.1067 in. 2.72-2.74 mm 2.75-2.77 mm 0.1071-0.1079 in. 0.1083-0.1091 In. 2.78-2.80 mm 0.1094-0.1 102 in. 2.81-2.83 mm 0.1106-0.1114 in. 2.84-2.86 mm 0.1118-0.1126 in. 2.87-2.89 mm 2.90-2.92 mm 2.93-2.95 mm 2.96-2.98 mm 0.1130-0.1138 In. 0.1142-0.1150 in. 0.1154-0.1161 In. 0.1165-0.1173 in. 2.99-3.01 mm 0.1 177-0.1 185 in. 3.02-3.04 mm 3.05-3.07 mm 0.1189-0.1197 in. 0.1201-0.1209 In. 3.08-3.10 mm 0.1213-0.1220 in. 3.1 1-3.13 mm 0.1224-0.1232 in. 3.14-3.16 mm 3.17-3.19 mm 0.1236-0.1244 in. 0.1248-0.1256 in. 3.20-3.22 mm 0.1260-0.1268 in. 3.23-3.25 mm 0.1272-0.1280 in. 3.26-3.28 mm 0.1283-0.1291 in. 3.29-3.31 mm 0.1295-0.1303 in. 3.32-3.34 mm 3.35-3.37 mm 0.1307-0.1315 in. 0.1319-0.1327 in. 3.38-3.40 mm 3.41-3.43 mm 3.44-3.46 mm 3.47-3.49 mm 0.1331-0.1339 in. 0.1343-0.1350 in. 0.1354-0.1362 in. 0.1366-0.1374 in.
Specifications (Cont'd) SERVICE SPECIFICATIONS - Rear Axle and Sus~ension A-29 Rear suspension No 1 lower suspension arm boll joint turning torque Upper arm boll joint turning torque 8.5-35.0 kg-cm 7-30 in.-lb 0.8-3.4 N.m 10-35 kg-cm 9-30 in.-lb 1.0-3.4 N,m Torque Specifications Axle hub and rear suspenslon Part tightened Axle carrier x Drive shaft Axle carrier x Shock absorber Axle carrier x Ugper arm Axle carrier x No. 1 suspenslon arm Axle carrier x No. 2 suspension arm Axle carrier x Strut rod Axle carrier x Backing plate Bolt Nut Axle carrier x Torque plate Body x Suspension support Shock absorber x Suspension support Body x Upper arm Body x No. 1 suspension arm Body x No. 2 suspension arm Body x Strut rod Body x Stabilizer bar bracket Stabilizer bar x Link kg-cm ft-lb N.m Drive shaft and differential Drive shaft x Differential Body x Differential Carr~er x Carrier cover Carr~er x Drain plug Carrier x F~ller plug Carr~er x Side bearing cap Ring gear x Differential case Drive pinion x Companion flange Different~al case (LH x RH) Companion flange x Propeller shaft Stud bolts Nuts Rear bolts Front bolts 700 5 1 69 800 58 78 930 67 91 930 67 91 1,690 122 166 475 34 47 500 36 49 500 36 49 800 58 78 985 71 97 See page RA-39 480 35 47 750 54 74
A-30 SERVICE SPECIFICATIONS - Brake Svstern BRAKE SYSTEM Specifications Brake pedal Brake booster Pedal height (from asphalt sheet) Pedal freeplay Pedal reserve distance at 50 kg (110.2 I b, 490 N) Booster push rod to piston clearance wisst 151.5-161.5 mm 5.96-6.36 in. 3-6mm 0.12-0.24 in. More than 80 mm (3.15 in.) Front brake Pad thickness 0.394 in. 0.039 in. Disc thickness 0.866 in. 0.827 in. Disc runout 0.0051 in. Rear brake Pad thickness 0.394 in. 0.039 in. Disc thickness 0.709 in. 0.669 in. Disc runout 0.0051 in Parking brake Lining thickness Rear drum inner diameter Lever travel at 20 kg (44.1 Ib, 196 N) Clearance between rear shoe and lever Parking brake shoe lever shim th~ckness 2.5 mm 0.098 in. 1.0 mm 0.039 in. 190 mm 7.48 in. 191 mm 7.51 in. 5-8 clicks 0-0.35 mm 0-0.0138 in. 0.3 mm 0.012 in. 0.6 mm 0.024 in. 0.9 mm 0.035 in. 'orque Specifications Part tightened kg-cm ft-lb N.m Bleeder plug 85 74 in.-lb 8 Master cylinder x Piston stopper bolt 1 100 7 10 Master cylinder x Reservo~r Master cyl~nder x Brake booster Brake tube union nut Brake booster clev~s lock nut Brake booster x Pedal bracket Front disc brake cylinder x Torque plate 370 27 36 Front disc brake hose bracket 1 195 14 19 Front disc brake torque plate x Steering knuckle Front disc brake cylinder x Flexible hose Front disc brake dust cover x Steering knuckle Rear disc brake cylinder x Torque plate 1 200 14 20 1 Rear disc brake torque plate x Rear axle carrier 475 Rear disc brake cylinder x Flexible hose 235 Rear disc brake backing plate x Rear axle carrier Nut 600 43 59 Bolt 260 19 25
Torque Specifications (Cont'd) SERVICE SPECIFICATIONS - Brake System, Steering A-3 1 Part tightened kg-cm ft-l b N.m I Parking brake shoe guide plate set bolt 1 185 13 18 Brake actuator x Actuator bracket Front speed sensor installation bolt Rear speed sensor installation bolt A340 E, R 1 54 STEERING Specifications W58 55 48 in.-lb 5.4 195 14 19 160 12 16 290 2 1 2 8 Steering Steering wheel freeplay 30 mm (1.18 in.) or less Tilt and telescopic steering No. 1 collar outer diameter 0.7082-0.7085 in. 0.7085-0.7088 in. 0.7088-0.7091 in. 0.7091-0.7093 in. 0.7093-0.7096 in. No. 2 collar outer diameter 0.7082-0.7085 in. 0.7085-0.7088 in. 0.7088-0.7091 in. 0.7091-0.7093 in. 0.7093-0.7096 in. Support shim th~ckness Mark None 5 8 14 18 0.0078-0.0080 in. 0.0195-0.0199 in. 0.0313-0.0317 in. 0.0549-0.0533 in. 0.0707-0.071 1 in. Power steering Drive belt tension Maximum rise of oil level New belt Used belt 160 + 20 1b 100 + 20 1b Below 5 mm (0.20 in.) Oil pressure Steering effort USA CANADA at Idle speed w/o PPS wl PPS wlo PPS 75-80 kg/cm2 (1,067-1,138 psi, 7,355-7,845 kpa) 4.7 kg (10.36 Ib, 46 N) or less 2.7 kg (5.95 Ib, 26 N) or less 70 kg-cm (61 in.-lb, 6.9 N.m) or less Rotor shaft bushing oil clearance Vane plate to rotor groove clearance Vane plate Minimum height Minimum thickness Minimum length wl PPS Maximum 40 kg-cm (34 in.-lb, 3.9 N.m) or less 0.01-0.03 mm 0.0004-0.0012 in. 0.07 mm 0.0028 in. 0.03 mm 0.0012 in. 8.1 mm 0.319 in. 1.797 mm 0.0707 in. 14.988 mm 0.5901 in.
A-32 SERVICE SPECIFICATIONS - Steering Specifications (Cont'd) Power steering (cont'd) Vane plate length Flow control valve sprlng length Pump rotating torque Steering rack runout Bearing preload (wlo PPS) Total preload Rotor and cam rlng mark None 1 2 3 4 Min~mum Maximum 14.996-14.998 mm 0.5904-0.5905 in. 14.994-14.996 mm 0.5903-0.5904 In. 14.992-14.994 mm 0.5902-0.5903 in. 14.990-14.992 mm 0.59016-0.59024 In. 14.988-14.990 mm 0.5901-0.5902 In. 39 mm 1.54 in. 37 mm 1.46 in. 2.8 kg-cm (2.4 ~n.-lb, 0.3 N.m) or less 0.3 mm 0.012 in. 4.5-6.5 kg-cm (3.9-5.6in.-lb,0.4-0.6N.m) 9-12 kg-cm (7.8-10.4 in.-lb, 0.9-1.2 N,m) Torque Specifications Tilt steering and telescopic steering Power steering Part tightened Support stopper bolt Tilt lever retainer Tilt lever retainer x Breakaway bracket (USA) No. 1 tilt sub lever bolt Column tube x Breakaway bracket Retainer Bracket x Column tube Main shaft x lntermediate shaft Column tube stopper bolt Telescopic lever x Telescopic lever bolt Breakaway bracket x Body lntermediate shaft x Universal joint Universal joint x Control valve shaft Steering wheel x Main shaft Column hole cover x Hole cover plate Column hole cover x Body Steering wheel pad (USA) Pressure port union x Pump housing Suction port union x Pump housing Air control valve x Pump housing PS pump pulley x Rotor shaft Front housing x Rear housing Drive belt adjust stay bolt 12 mm bolt 14 mm bolt PS pump x Pressure tube PS pump x Bracket PS pump x Adjust bracket Reservoir tank installation bolt () Nut Bolt Adjusting strut () Nut Bolt kg-cm ft-lb N.m 8 11 14 19 69 in.-lb 7.8 69 in.-lb 7.8 14 19 20 27 19 25 69 in.-lb 7.8 10 14 19 25 24 32 24 32 25 34 9 13 48 in.-lb 5.4 65 in.-lb 7.4
Torque Specifications (Cont'd) SERVICE SPECIFICATIONS - Steering, SRS Airbag A-33 Power steering (cont'd) Part tightened Pressure control valve x Control valve housing (w/ PPS) Control valve housing x Rack housing w/o PPS W/ PPS Control valve self-locking nut (w/ PPS) Rack housing cap (wl PPS) Bearing guide lock nut (wlo PPS) Rack guide spring cap lock nut Rack x Rack end Turn pressure tube x Gear housing Valve housing (wlo PPS) (w/ PPS) Rack housing Gear housing x Body Gear housing x Return line w/o PPS W/ PPS Gear housing x Pressure line wlo PPS w/ PPS Tie rod end x Steering knuckle Control valve shaft x Universal joint Tie rod end clamp bolt kg-cm ft-lb N.m Specifications Front airbag sensor resistance Terminal (3s i/ - OA I?&,s- g s @S-@A 00 Less than 1 R Torque Specifications -- Part tightened kg-cm ft-lb N.m Steering wheel Steering wheel pad Front airbag sensor Center airbag sensor assembly
A-34 SERVICE SPECIFICATIONS - Body BODY Torque Specifications Part tightened kg-cm ft-l b N.m SEAT Front Seat Seat back x Seat adjuster Seat cushion x Seat adjuster Seat adjuster x Body Rear Seat Seat back lock x Seat back Seat back lock striker x Body Seat center hinge x Seat back Seat center hinge x Body Seat back hinge x Seat back Seat back hinge x Body SEAT BELT Front Seat Belt ELR x Body Outer belt shoulder anchor x Body Outer belt lower anchor x Body lnner belt x Bracket Bracket x Seat cushion Anchor plate x Body Rear Seat Belt ELR x Body Outer belt shoulder anchor x Body Outer belt lower anchor x Body lnner belt x Body
SERVICE SPECIFICATIONS - Lubricant A-35 LUBRICANT l tem Liters Capacity US qts Imp. qts Classification Engine oil () Dry fill Drain and refill API grade SF or SFICC, multigrade viscosity oil W/ Oil filter change W/O Oil filter change () Dry fill Drain and refill W/ Oil filter change W/O Oil filter change Manual transmission oil I W58 API G L-4 or G L-5 SAE 75W-90 or 80W-90 R154 API GL-4 or GL-5 SAE 75W-90 Automatic transmission fluid ATF DEXRONQII Dry fill Drain and refill Differential oil API GL-5 hypoid gear oil w/lsd Use LSD oil only Above -18 C (o F) SAE 90 Below -18 C (0 F) SAE 80W-90 or 80W Power steering fluid Total Brake fluid Antifreeze 1,000 cc 61.0 cu in. ATF DEXRON@II SAE J1703 or FMVSS No. 116, DOT3 Anti-rust type ethylene-glycol base coolant
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